ginnie, you hadn't mentioned before my reply that your friend said she wants a quilt.
Now I say that making one of his clothing sounds soooo comforting and wonderful. About advice tips, the one thing I've heard is that lightweight tee-shirt material needs a backing but I don't know how or with what. Somebody here will, I'm sure. At his age, that was probably his primary wardrobe.
You are to be commended for your very compassionate undertaking.